Multi-part electronic device housing having contiguous filled surface

ABSTRACT

A housing for an electronic device that allows electromagnetic waves to pass through the housing is disclosed. The housing may include a first portion having an opening, a second portion positioned within the opening, and an insert including a protrusion extending into at least a portion of a gap formed between the first portion and the second portion. The housing also may include a first ink layer disposed within the gap and substantially surrounding the protrusion, and a second ink layer disposed within the gap and over the first ink. The first portion, second ink layer, and second portion may cooperate to form a substantially contiguous surface, and the second ink layer may be positioned approximately 5 microns (μm) or less below an exposed surface of the first portion and an exposed surface of the second portion.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a nonprovisional patent application of U.S.Provisional Patent Application No. 62/235,315, filed Sep. 30, 2015 andtitled “Multi-Part Electronic Device Housing Having Contiguous FilledSurface,” the disclosure of which is hereby incorporated by referenceherein in its entirety.

FIELD

The disclosure relates generally to electronic devices and moreparticularly to a housing for an electronic device that allowselectromagnetic waves to pass through the housing.

BACKGROUND

Conventional electronic devices typically include various communicationcomponents that are capable of providing and/or receiving data fromother electronic devices. For example, most electronic devices includean antenna that is utilized to send and/or receive data for theelectronic device wirelessly. The antenna is typically embedded orpositioned within the enclosure or housing of the electronic device toprevent the antenna from being damaged and incapable of sending orreceiving data for the electronic device. However, the enclosures orhousings for the electronic devices are typically solid (e.g., formedfrom a single piece) to improve strength for the electronic device, tohouse and protect the internal components of the electronic deviceand/or to prevent contaminants (e.g., dust, water and other particles)from entering the housing and damaging the internal components of theelectronic device. The solid enclosure and/or housing can negativelyimpact the operation of the antenna of the electronic device by makingit difficult for the electromagnetic waves of the antenna to passthrough the housing when sending and/or receiving data.

As such, enclosures and/or housings can include breaks or openings toimprove the transmission of the electromagnetic waves for the antennathrough the housing. However, forming breaks or openings in the housingmakes the electronic device and its internal component more susceptibleto damage (e.g., ingress for contaminants, weakened component).Additionally, where a distinct component (e.g., door, plug) ispositioned within the break or opening, the gap formed therebetween cangrow and/or vary in size over the operational life of the electronicdevice as a result of the coupling between the distinct component andthe remainder of the enclosure or housing wearing and/or failing.

SUMMARY

A housing for an electronic device is disclosed. The housing comprises:a first portion comprising an opening; a second portion positionedwithin the opening; a protrusion extending into a gap formed between thefirst portion and the second portion; a first ink layer disposed withinthe gap and substantially surrounding the protrusion; and a second inklayer disposed within the gap and over the first ink layer; wherein thefirst portion, second ink layer, and second portion cooperate to form asubstantially contiguous surface; and the second ink layer is positionedapproximately 5 microns (μm) or less below an exposed surface of thefirst portion and an exposed surface of the second portion.

A method for forming a housing for an electronic device is disclosed.The method comprises coupling an insert to a first portion and a secondportion of the housing, extending a protrusion of the insert within agap between the first portion and second portion; disposing a first inklayer within the gap; curing the first ink layer; disposing a second inklayer within the gap and over the first ink layer, an exposed surface ofthe first portion, and an exposed surface of the second portion;smoothing at least part of the second ink layer; and curing the secondink layer; wherein a top surface of the second ink layer is within 10microns of a top surface of the second portion of the housing.

An electronic device is disclosed. The electronic device comprises ahousing including a body comprising an opening formed in an end of thehousing, and an antenna window positioned within the opening of thebody. The antenna window is separated from the body via a gap. Theelectronic device also comprises a plastic insert coupled to the housingand the antenna window. The insert comprises a protrusion extending intoa portion of the gap between the housing and the antenna window.Additionally, the electronic device comprises at least one ink layerdisposed within the gap. The at least one ink layer is exposed betweenthe housing and the antenna window.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1A shows a back view of an electronic device including a housingformed from a body portion and an antenna window;

FIG. 1B shows an enlarged view of a portion of the housing formed fromthe body portion and the antenna window as shown in FIG. 1A;

FIG. 2 shows a cross-section view of a portion of the housing formedfrom the body portion and the antenna window taken along line 2-2 inFIG. 1B;

FIG. 3 shows a flow chart of an example process for forming a housingfor an electronic device;

FIG. 4A shows an enlarged view of a portion of a housing for anelectronic device formed from a body portion and an antenna window;

FIG. 4B shows a cross-section view of a portion of the housing formedfrom the body portion and the antenna window taken along line 4B-4B inFIG. 4A;

FIG. 4C shows an enlarged view of the portion of the housing of FIG. 4Aafter a first ink layer is applied in a gap;

FIG. 4D shows a cross-section view of a portion of the housing of FIG.4C taken along line 4D-4D;

FIG. 4E shows a cross-section view of a portion of the housing of FIG.4C taken along line 4D-4D subsequent to the first ink layer being cured;

FIG. 4F shows an enlarged view of the portion of the housing of FIG. 4Cafter a second ink layer is applied to the housing;

FIG. 4G shows a cross-section view of a portion of the housing of FIG.4F taken along line 4G-4G;

FIG. 4H shows an enlarged view of the portion of the housing of FIG. 4Fafter a portion of the second ink layer is removed from the housing;

FIG. 4I shows a cross-section view of a portion of the housing of FIG.4H taken along line 4I-4I;

FIG. 4J shows a cross-section view of a portion of the housing of FIG.4H taken along line 4I-4I subsequent to the second ink layer beingcured;

FIG. 4K shows an enlarged view of the portion of the housing of FIG. 4Hafter a remaining portion of the second ink layer is removed from thebody and antenna window of the housing;

FIG. 4L shows a cross-section view of a portion of the housing of FIG.4K taken along line 4L-4L;

FIG. 5 shows a cross-section view of a portion of a housing formed froma body portion and an antenna window;

FIG. 6A shows a front view of an electronic device including a housingformed from a body portion and an antenna window; and

FIG. 6B shows a back view of the electronic device of FIG. 6A.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings. It should be understood thatthe following descriptions are not intended to limit the embodiments toone preferred embodiment. To the contrary, it is intended to coveralternatives, modifications, and equivalents as can be included withinthe spirit and scope of the described embodiments as defined by theappended claims.

The following disclosure relates generally to electronic devices andmore particularly to a housing for an electronic device that allowselectromagnetic waves to pass through the housing.

In a particular embodiment, a housing for an electronic device isconfigured to allow electromagnetic waves from an antenna of theelectronic device (or other electronic component) to pass through thehousing without substantial attenuation or being blocked. The housingincludes two distinct portions that are separated by a gap. The gapformed between the first portion and the second portion is sized toallow electromagnetic waves from the antenna to pass through thehousing, between the two distinct portions. The gap may be filled by afiller or multiple fillers, which may (or may not) be transparent toantenna frequencies. In some embodiments, an ink, resin, latex, or othersuitable material may form a top surface of the filler or fillers suchthat the top surface is flush or near-flush with the two distinctportions.

Components of the housing (e.g., the fillers) are positioned and/ordisposed in the gap to provide structure to the housing, prevent thesize of the gap from varying over the operational life of the electronicdevice, and provide a surface between the two portions of the housingthat feels contiguous to a user of the housing. In certain embodiments,the user may not be able to tactilely perceive difference in depthand/or height between the housing components and a top surface of afiller in the gap. Further, in some embodiments the fillers improve theappearance of the housing, including the gap.

In the particular embodiment, an insert can be coupled to the twoportions of the housing for securing the portions to one another andsetting the size of the gap formed therebetween. Additionally, aprotrusion of the insert can be positioned within the gap to provideadditional support and rigidity to the separate portions of the housing.At least one layer of ink can also be disposed within the gap over theprotrusion of the insert and can seal the gap between the two portionsof the housing. The ink disposed in the gap can be formed such that thesurface of the ink is contiguous with or positioned below the surface ofthe housing by a small distance (e.g., less than approximately 5 microns(μm), 10 microns (μm), or the like), such that the ink in the gapcreates a transition between the two portions of the housing that feelscontiguous and/or lacks discontinuities that are tactilely and/orvisually perceptible. As such, although the housing is formed from twodistinct portions, the ink disposed in the gap makes the transition fromand/or over the surface of the housing between the two portionstactilely and/or visually imperceptible to a person; in someembodiments, the housing feels continuous, smooth and/or uniform.

These and other embodiments are discussed below with reference to FIGS.1A-6B. However, those skilled in the art will readily appreciate thatthe detailed description given herein with respect to these Figures isfor explanatory purposes only and should not be construed as limiting.

FIG. 1A shows an electronic device including a housing according toembodiments. The electronic device 100 shown in FIG. 1A includes anantenna (not shown) positioned within the housing 102 for transmittingand receiving electromagnetic waves to communicate and/or provideelectronic information to other electronic devices wirelessly. In orderto transmit and receive electromagnetic waves, a break or separation isformed in housing 102 to allow the electromagnetic waves to pass toand/or from the antenna and through housing 102. As discussed below indetail, housing 102 includes two distinct parts or portions that allowthe electromagnetic waves to pass through housing 102 without disruptionor disturbance. The two distinct portions of housing 102 are separatedby a gap that is sized to aid in allowing electromagnetic waves from theantenna of electronic device 100 to pass through housing 102, betweenthe two distinct portions. As discussed herein, components of housing102 and/or electronic device 100 are positioned and/or disposed withinthe gap to provide structure to housing 102 and/or prevent the size ofthe gap from varying during the operational life of electronic device100. In addition to providing structural support and benefits, and asdiscussed herein, additional components can be disposed within the gapformed in housing 102 to make housing 102 feel contiguous and/or lackdiscontinuities that are tactilely and/or visually perceptible when auser touches and/or looks at housing 102 formed from two distinctportions.

As shown in FIG. 1A, housing 102 of electronic device 100 includes afirst portion or a main body portion 104 (hereafter, “body 104”). Body104 of housing 102 includes the majority of the structure or materialforming housing 102 for electronic device 100. In a non-limitingexample, body 104 of housing 102 includes and/or houses substantiallyall of the internal components of electronic device 100, including theantenna (not shown) for electronic device 100. Body 104 of housing 102includes a recess, cutout or opening 106 formed on an end 108 of housing102. As shown in FIG. 1A, and additionally shown in the enlarged portionof electronic device 100 in FIG. 1B, recess or opening 106 extends intoand/or through a substantially small portion of housing 102 at end 108.Additionally, opening 106 is formed in and/or through only a portion ofthe width of housing 102 at end 108.

Housing 102 also includes a second portion or an antenna window 110. Asshown in FIGS. 1A and 1B, antenna window 110 is positioned withinopening 106 of body 104. That is, antenna window 110 is positionedwithin opening 106 and is at least partially surrounded by body 104 ofhousing 102. Antenna window 110 is smaller than opening 106 formed inbody 104 at end 108 of housing 102. As such, when antenna window 110 isinserted and/or positioned within opening 106 formed in body 104, aseparation or gap (G) exists (see, FIG. 1B) between body 104 and antennawindow 110 of housing 102. The separation or gap (G) formed between body104 and antenna window 110 is sized to allow the antenna of electronicdevice 100 to transmit and/or receive electromagnetic waves throughhousing 102 and/or between body 104 and antenna window 110, as discussedherein. The gap is sized by forming opening 106 and/or antenna window110 to have a predetermined dimension, such that when antenna window 110is inserted and/or positioned within opening 106, the gap (G) betweenbody 104 and antenna window 110 exists. Additionally as discussedherein, the gap (G) formed between body 104 and antenna window 110includes additional components formed therein, where the additionalcomponents also aid in the formation of the gap (G) between body 104 andantenna window 110 of housing 102.

Housing 102, and the distinct portions forming housing 102, are formedfrom similar materials or materials having substantially similarproperties and characteristics. Specifically, body 104 and antennawindow 110 can be formed from similar materials, or alternatively, canbe formed from distinct materials. In the non-limiting example wherebody 104 and antenna window 110 are formed from the same material, body104 and antenna window 110 can be formed from the same piece ofmaterial. That is, a single sheet or piece of material can be formed totake the desired shape of housing 102, and can be subsequently cut toform opening 106 in body 104. The removed or cut portion of the materialcan undergo further material processing (e.g., grinding, cutting,shaping and so on) to form antenna window 110. Additionally orseparately, opening 106 can undergo additional material processing toensure that antenna window 110 formed from the removed or cut portion ofthe single piece of material can be positioned within opening 106 and agap (G) can be formed therebetween. Body 104 and antenna window 110 canbe formed from various materials that provide a rigid structure forsupporting electronic device 100 and/or protecting the internalcomponents of electronic device 100, such as, but not limited to, metalsor metal alloys. In a non-limiting example, both body 104 and antennawindow 110 can be formed from aluminum. In another non-limiting example,one of body 104 or antenna window 110 can be formed from aluminum, andthe other component (e.g., body 104, antenna window 110) forming housing102 can be formed from a distinct metal alloy, such as titanium,chromium or steel.

FIG. 2 shows a cross-section view of housing 202 taken along line 2-2 inFIG. 1B. Specifically, FIG. 2 shows a cross-section of body 204, antennawindow 210 and additional components of housing 202. It is understoodthat similarly numbered and/or named components may function in asubstantially similar fashion. Redundant explanation of these componentshas been omitted for clarity.

As shown in FIG. 2, housing 202 includes an insert 212. Insert 212 ispositioned below, adjacent and/or between body 204 and antenna window210 of housing 202. Additionally, insert 212 is coupled or affixed tobody 204 and antenna window 210 of housing 202. Specifically, and asshown in FIG. 2, insert 212 is coupled to an interior surface 218 ofbody 204 and an interior surface 220 of antenna window 210,respectively. In a non-limiting example, insert 212 is adhered tointerior surface 218 of body 204 and interior surface 220 of antennawindow 210, respectively, using adhesive 222. In addition to adheringand/or coupling insert 212 to body 204 and antenna window 210,respectively, adhesive 222 can also be configured to seal the gap (G)formed between body 204 and antenna window 210. The sealing of the gap(G) can prevent contaminants (e.g., water, dust and other damagingparticles) from entering housing 202. It is understood that insert 212can be coupled to body 204 and antenna window 210 using other couplingmechanisms and/or techniques as well. In non-limiting examples, insert212 can be coupled to body 204 and antenna window 210 using tape,solder, fasteners (e.g., screws, snap-fits, and so on) and the like.

In addition to adhering insert 212 to body 204 and antenna 210, adhesive222 can also act as a shim within housing 202. Specifically, thethickness and/or amount of adhesive 222 positioned between insert 212and body 204/antenna window 210 can create an “offset” and/or a spacebetween insert 212 and body 204/antenna window 210. This offset canalter size, and specifically the depth, of the gap (G) formed betweenbody 204 and antenna window 210. As discussed herein, the depth of thegap (G) formed in housing 202 impacts and/or influences a thicknessand/or an amount of ink(s) that can be disposed within the gap (G).Although adhesive 222 is discussed as creating the offset between insert212 and body 204/antenna window 210, it is understood that any couplingcomponent formed between insert 212 and body 204/antenna window 210 forcoupling the components can create and/or influence the offset.

Insert 212 also includes a protrusion 224. Protrusion 224 extends fromthe portion of insert 212 positioned below and/or coupled to body 204and antenna window 210. Additionally, protrusion 224 extends betweenbody 204 and antenna window 210, and/or is positioned within a portionof the gap (G) formed between body 204 and antenna window 210. As shownin FIG. 2, the positioning of protrusion 224 between body 204 andantenna window 210 impacts and/or influences the size of the gap (G)formed between body 204 and antenna window 210. Specifically, the gap(G) formed between body 204 and antenna window 210 can be no smallerthan protrusion 224 of insert 212. As a result, protrusion 224 mayinclude a width and/or size that may correspond to the minimum sizerequired for the gap (G) to allow electromagnetic waves from the antenna(not shown) of an electronic device (see, FIG. 1A) to pass throughhousing 202 and/or between body 204 and antenna window 210, as discussedherein.

Additionally as shown in FIG. 2, protrusion 224 is positioned below anexposed surface 226 of body 204 and an exposed surface 228 of antennawindow 210. That is, protrusion 224 of insert 212 is positioned belowexposed surface 226 of body 204 and exposed surface 228 of antennawindow 210, such that protrusion 224 is not visible in housing 202. In anon-limiting example, protrusion 224 of insert 212 can be positionedbelow exposed surface 226 of body 204 and exposed surface 228 of antennawindow 210 at a distance between approximately 50 microns (μm) andapproximately 200 μm, and/or 5 to 100 microns in particular embodiments.As discussed herein, additional components of housing 202 are positionedwithin the gap (G) between body 204 and antenna window 210 and/or aredisposed over protrusion 224. In some embodiments, the distance betweenthe protrusion's top surface and the exposed surface(s) may set a totaldepth of one or more ink layers or other fillers.

As shown in FIG. 2, insert 212 including protrusion 224 is formed as asingle, integral component or structure. However, it is understood thatprotrusion 224 can be formed from a distinct piece or component and canbe coupled to insert 212 using any of the coupling mechanisms and/orcoupling techniques discussed herein. Additionally, insert 212 includingprotrusion 224 can be formed from a substantially rigid component thancan hold body 204 and antenna window 210 in place within housing 202. Ina non-limiting example, insert 212 can be formed from a polymer, such asplastic.

Housing 202, as shown in FIG. 2, can also include filler(s) such as afirst ink layer 230 disposed within the gap (G) formed between body 204and antenna window 210. Additionally, first ink layer 230 is disposedwithin the gap (G) and substantially surrounds, covers, and/or masksprotrusion 224 of insert 212. As shown in FIG. 2, portions of first inklayer 230 are disposed around protrusion 224 of insert 212 and arepositioned between body 204 and protrusion 224, and antenna window 210and protrusion 224, respectively. As such, first ink layer 230 can beformed between body 204 and protrusion 224, and antenna window 210 andprotrusion 224, respectively, to ensure the gap (G) formed between body204 and antenna window 210 is adequately sized to allow electromagneticwaves to be transmitted through housing 202 and/or the gap (G).Additionally, first ink layer 230 can also be formed or disposed betweenbody 204 and protrusion 224, and antenna window 210 and protrusion 224,respectively, to seal the gap (G) of housing 202.

Additionally as shown in FIG. 2, first ink layer 230 is positioned belowportions of body 204 and antenna window 210, respectively. Specifically,a surface 232 of first ink layer 230 disposed in the gap (G) formedbetween body 204 and antenna window 210 is positioned below exposedsurface 226 of body 204 and exposed surface 228 of antenna window 210,respectively. In some embodiments, surface 232 of first ink layer 230 isformed below exposed surface 226 of body 204 and exposed surface 228 ofantenna window 210, respectively, to make additional room within the gap(G) formed between body 204 and antenna window 210 for a second inklayer, although this is not necessary or contemplated in allembodiments. Other embodiments may form the surface 232 at or even abovethe exposed surfaces 226, 228.

First ink layer 230 is formed from a first curable colored ink. Thecolor of the ink forming first ink layer 230 is dependent on, at leastin part, the color of body 204 and antenna window 210. Additionally, theamount of the first curable colored ink forming the first ink layer 230that is disposed over protrusion 224 is dependent upon the color of theink. That is, the thickness and/or the amount of curable colored inkdisposed within the gap (G) is dependent upon the color of the curablecolored ink forming the first ink layer 230 and/or the desired color tobe perceived through a second ink layer, as discussed herein. In anon-limiting example, the thickness and/or amount of a curable coloredink forming a black first ink layer 230 can be substantially less than athickness and/or amount of a curable colored ink forming a light grayfirst ink layer 230. The thickness and/or amount of the black ink can besmaller because the black ink is more opaque, and therefore is more trueto color and/or requires less color to achieve a desired color (e.g.,black) visible and/or perceived in the gap (G) formed in housing 202.

Additionally, by disposing first ink layer 230 formed from colored inkwithin the gap (G), the visible color of the ink disposed in the gap (G)can be constant, uniform and/or include less variation for housing 202.That is, because the visible color of the gap (G) formed within housing202 is directly dependent upon the colored ink forming first ink layer230 disposed between body 204 and antenna window 210, the quality and/orconsistency of the visible color can be controlled by the amount of inkdisposed within the gap (G). In non-limiting examples, the intensity,the consistency/uniformity and/or the variation of the visible color offirst ink layer 230 disposed and visible in gap (G) of housing 202 canbe improved by altering the amount and/or thickness of first ink layer230.

Housing 202 can also include second ink layer 234 and, in someembodiments, additional ink layers beyond the second. As shown in FIG.2, second ink layer 234 is disposed and/or formed within the gap (G)formed between body 204 and antenna window 210, and is formed overand/or surrounding first ink layer 230. Specifically, second ink layer234 is disposed, formed directly over and/or substantially coverssurface 232 of first ink layer 230. As similarly discussed herein withrespect to first ink layer 230, second ink layer 234 disposed within thegap (G) formed between body 204 and antenna window 210 can substantiallyseal the gap (G) formed between body 204 and antenna window 210.

As shown in FIG. 2, second ink layer 234 includes an exposed surface236, opposite surface 232 of first ink layer 230, that is positioned insubstantially planar alignment with exposed surface 226 of body 204 andexposed surface 228 of antenna window 210, respectively. In thisnon-limiting example, second ink layer 234 formed in gap (G) provides arelatively uniform transition between body 204 and antenna window 210 ofhousing 202. As one example, because exposed surface 236 (e.g., a topsurface of the fillers) is contiguous with exposed surface 226 of body204 and exposed surface 228 of antenna window 210, the transition acrosssecond ink layer 234 from body 204 to antenna window 210 feelscontiguous and/or lacks discontinuities that are typically associatedwith multi-part structures. Thus, the transition(s) may be tactilelyand/or visually imperceptible.

In another non-limiting example, discussed below in detail, exposedsurface 236 of second ink layer 234 can be positioned at substantiallythe same level as, or slightly below, exposed surface 226 of body 204and exposed surface 228 of antenna window 210, respectively. In thenon-limiting example, and as discussed in detail below, exposed surface236 of second ink layer 234 can be positioned below exposed surface 226of body 204 and exposed surface 228 of antenna window 210 at arelatively small distance. In some embodiments, this distance is lessthan approximately 5 microns, while in others it may be less thanapproximately 10 microns. As a result, second ink layer 234 disposed inthe gap (G) creates a transition between body 204 and antenna window 210that is tactilely and/or visually imperceptible for a user of housing202. It should be appreciated that tactile imperceptibility may not be afeature of all embodiments.

Second ink layer 234 is formed from a second curable ink. Unlike thefirst curable colored ink forming first ink layer 230, the secondcurable ink forming second ink layer 234 is substantially clear and/ortransparent. That is, the second curable ink forming second ink layer234 is formed to have substantially transparent and/or clear properties.As a result of the transparent or clear properties of the second curableink forming second ink layer 234, the first curable colored ink formingfirst ink layer 230 is visible within the gap (G) through second inklayer 234.

Additionally, the thickness and/or amount of the second curable inkforming second ink layer 234 that is disposed over first ink layer 230is dependent upon the thickness and/or amount of first ink layer 230disposed in the gap (G). That is, the thickness and/or the amount ofsecond curable ink disposed within the gap (G) is dependent upon thethickness and/or amount of first ink layer 230 disposed in the gap (G)and the amount of space in the gap that is unoccupied by protrusion 224and first ink layer 230. Additionally, the thickness and/or amount ofthe second curable ink forming second ink layer 234 that is disposedwithin the gap (G) is dependent on, at least in part, the finish and/ortexture to be achieved on exposed surface 236 of second ink layer 234.That is, the second curable ink forming second ink layer 234 can providea texture and/or a finish (e.g., gloss, matte, and so on) within the gap(G) formed between body 204 and antenna window 210 of housing 202. In anon-limiting example, the thinner and/or smaller amount of second inklayer 234 disposed in the gap (G), the less glossy second ink layer 234and first ink layer 230 will appear in the gap (G). As discussed herein,second ink layer 234 can also act as a protective layer for colored,first ink layer 230 to prevent first ink layer 230 from being removedfrom the gap (G) and/or prevent the gap (G) from becoming colorless ordiscontinuous in color.

The first curable ink forming first ink layer 230 and the second curableink forming second ink layer 234 can include similar, unique featuresthat aid in the formation of housing 202, as discussed herein. In anon-limiting example, both the first curable ink forming first ink layer230 and the second curable ink forming second ink layer 234 can beformed from a material that does not shrink and/or includes lowshrinkage during the curing process for each layer. As discussed herein,the non-shrinkage and/or low shrinkage of first ink layer 230 and secondink layer 234 aids in maintaining a uniform and planar transition overthe gap (G) between body 204 and antenna window 210.

Additionally in another non-limiting example, and as discussed herein,both first curable ink forming first ink layer 230 and the secondcurable ink forming second ink layer 234 can be chemically, materiallyand/or compositionally configured to bond to other curable ink andinsert 212 of housing 202. Specifically, first curable ink forming firstink layer 230 and the second curable ink forming second ink layer 234are compositionally configured to bond to other curable ink and insert212 formed from plastic when each of first ink layer 230 and second inklayer 234 are cured. In addition, first curable ink forming first inklayer 230 and second curable ink forming second ink layer 234 can bechemically, materially and/or compositionally configured to prevent,resist and/or minimize a bond with body 204 and antenna window 210 ofhousing 202. As discussed herein, the prevention and/or minimization ofthe bond formed between first ink layer 230 and second ink layer 234with body 204 and antenna window 210 allows for easier removal of secondink layer 234 that can be disposed over exposed surface 226 of body 204and/or exposed surface 228 of antenna window 210, when forming housing202.

FIG. 3 depicts an example process for forming a housing for electronicdevices. Specifically, FIG. 3 is a flowchart depicting one exampleprocess 300 for forming a housing for an electronic device that allowselectromagnetic waves from an antenna of the electronic device to passthrough the housing. In some cases, the housing is formed for anelectronic device discussed below with respect to FIGS. 6A and 6B.

In operation 302, an insert is coupled to a first portion or body of ahousing and a second portion or antenna window of the housing. Theinsert is coupled to the body and antenna window, respectively, byadhering the insert to each component of the housing. Specifically, theinsert is adhered to an interior surface of the body and adhered to aninterior surface of the antenna window, respectively. The interiorsurface of the body is positioned opposite an exposed surface of thebody, and the interior surface of the antenna window is positionedopposite an exposed surface of the antenna window. Coupling the insertto the body and antenna window also includes positioning a protrusion ofthe insert within at least a portion of a gap formed between the bodyand the antenna window. The gap formed between the body and the antennawindow is sized to allow electromagnetic waves from an antenna to passthrough the housing and/or between the body and the antenna window.

In operation 304, a first ink layer is disposed within the gap formedbetween the body and the antenna window of the housing. The first inklayer is disposed in a portion of the gap formed between the body andthe antenna window, and the first ink layer substantially covers theprotrusion of the insert positioned in a portion of the gap formedbetween the body and the antenna window. In addition, disposing thefirst ink layer within a portion of the gap can include disposing aportion of the first ink layer between the protrusion of the insert andthe body and/or the antenna window. Additionally, disposing the firstink layer within the gap can also include forming a surface of the firstink layer below the exposed surface of the body and the exposed surfaceof the antenna window. The first ink layer is disposed within the gapformed between the body and the antenna window using any suitabletechnique including, but not limited to, material injection using aneedle or syringe, jetting material, digital printing and/or precisionspraying. The first ink layer disposed in the gap includes a curable,colored ink.

In operation 306, the first ink layer is cured. Specifically, after thefirst ink layer is disposed within the gap formed between the body andthe antenna (e.g., operation 304), the first ink layer undergoes acuring process(es). Curing the first ink layer in operation 306 may alsoresult in the first ink layer shrinking. That is, as a result ofperforming the curing process on the first ink layer, the first inklayer can shrink in size. However, the chemical and/or materialcomposition of the curable, colored ink forming the first ink layer canbe a low and/or minimal shrinkage material. As such, the shrinking ofthe first ink layer that occurs during the curing process can besubstantially minimal and/or negligible. Additionally, curing the firstink layer can include bonding the first ink layer to the protrusion ofthe insert. That is, as the first ink layer is cured, the first inklayer is also bonded to the protrusion of the insert which the first inklayer substantially covers.

In operation 308, a second ink layer is disposed within the gap formedbetween the body and the antenna window of the housing. Additionally,the second ink layer is over-disposed and/or printed outside of the gapand onto a portion of the body and the antenna window. As such, thesecond ink layer is disposed over the first ink layer disposed withinthe gap, a portion of the exposed surface of the body and a portion ofthe exposed surface of the antenna window. Additionally, disposing thesecond ink layer also includes temporarily forming an exposed surface ofthe second ink layer above and/or onto the exposed surface of the bodyand the exposed surface of the antenna window. Similar to the first inklayer, the second ink layer is disposed in operation 308 using anysuitable technique including, but not limited to, material injectionusing a needle or syringe, jetting material, digital printing and/orprecision spraying. The second ink layer includes and/or is formed froma curable, clear or transparent ink.

In operation 310, at least a part of the second ink layer is removed.Specifically, at least a part of the second ink layer disposed over thefirst ink layer, the exposed surface of the body and/or the exposedsurface of the antenna window is removed. The removal process inoperation 310 includes scraping at least a part of the uncured secondink layer from the exposed surface of the body and the exposed surfaceof the antenna window. The second ink layer is removed or scraped fromthe housing using an ink removal tool. The ink removal tool includes anysuitable tool configured to remove the uncured ink forming the secondink layer including, but not limited to, a blade, a scraper, a flexibleremoval tool, or the like.

In operation 312, the second ink layer is cured. Specifically, after atleast a part of the second ink layer is removed in operation 310, thesecond ink layer undergoes a curing process(es). Similar to the firstink layer discussed herein with respect to operation 306, curing thesecond ink layer may result in the second ink layer shrinking. However,the chemical and/or material composition of the curable, clear inkforming the second ink layer can be a low and/or minimal shrinkagematerial, and the second ink layer may only shrink a substantiallyminimal and/or negligible amount when cured.

Additionally, curing the second ink layer can include bonding the secondink layer to the first ink layer formed or disposed within the gapformed between the body and the antenna window of the housing. Curingthe second ink layer can also include substantially preventing a bondfrom forming between the second ink layer and the exposed surface of thebody and/or the exposed surface of the antenna window. Specifically,when the second ink layer is cured, the parts of the second ink layerthat remain on the body and the antenna window and/or are not removed inoperation 310 are prevented from bonding to the exposed surface of thebody and/or the antenna window. The bonding to the first ink layer andthe prevention of a bond forming on the exposed surfaces of the bodyand/or antenna window, respectively, is a result of the chemical and/ormaterial composition of the curable clear ink forming the second inklayer and the material forming the first ink layer, the body and theantenna window.

In operation 314, any remaining part of the second ink layer disposedanywhere but within the gap is removed. That is, the remaining parts ofthe second ink layer disposed over the exposed surface of the body andthe exposed surface of the antenna window are removed. By removing theseremaining parts, the second ink layer is only disposed and/or positionedwithin the gap formed between the body and the antenna window. Theremoval of the remaining parts of the second ink layer in operation 314includes exposing the remaining part of the cured second ink layer to asolvent (e.g., isopropyl alcohol), and wiping away, smoothing, and/orremoving the remaining part of the cured second ink layer dissolved bythe solvent.

FIGS. 4A-4L show body 404 and antenna window 410 undergoing the process300 for forming housing 402 as shown and discussed herein with respectto FIG. 3. Specifically, FIGS. 4A-4L show front and cross-section endviews of the various components forming housing 402 undergoing theprocess 300 discussed herein. The various components shown in FIGS.4A-4L are substantially similar to those shown and discussed herein withrespect to FIGS. 1A-2. It is understood that similarly numbered and/ornamed components may function in a substantially similar fashion.Redundant explanation of these components has been omitted for clarity.

FIG. 4A shows a front view of a portion of body 404 and antenna window410 according to embodiments. Additionally, FIG. 4B shows across-section view of body 404 and antenna window 410 of FIG. 4A, takenalong line 4B-4B. As shown in FIGS. 4A and 4B, antenna window 410 ispositioned within opening 406 formed in body 404 such that a gap (G) isformed between body 404 and antenna window 410. As discussed herein, thegap (G) is formed to allow electromagnetic waves to pass through housing402 and/or between body 404 and antenna window 410.

Additionally shown in FIG. 4B, insert 412 is coupled and/or adhered tobody 404 and antenna window 410, respectively. Specifically, insert 412is adhered to interior surface 418 of body 404 and interior surface 420of antenna window 410 using adhesive 422. As a result of coupling and/oradhering insert 412 to body 404 and antenna window 410, protrusion 424of insert 412 is positioned within a portion of the gap (G) formedbetween body 404 and antenna window 410. As shown in FIG. 4B, wheninsert 412 is coupled to body 404 and antenna window 410, a surface 438of protrusion 424 is positioned within the gap (G) and below exposedsurface 426 of body 404 and exposed surface 428 of antenna window 410,respectively.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIGS. 4A and 4B corresponds tooperation 302 of the process 300 shown in FIG. 3.

FIGS. 4C and 4D show first ink layer 430 being disposed, provided and/orformed in the gap (G) (see, FIGS. 4A and 4B). Specifically, first inklayer 430 is disposed into the gap (G) formed between body 404 andantenna window 410, and is disposed over protrusion 424 includingsurface 438 (see, FIG. 4D). As shown in FIG. 4C, first ink layer 430 isdisposed within the gap (G) using an ink dispensing component 440. In anon-limiting example, ink dispensing component 440 is configured as amaterial injection component using a needle or syringe for disposingfirst ink layer 430 within the gap (G). In other non-limiting examples,ink dispensing component 440 can include a material jetting component orsystem, a digital material printing system and/or precision sprayingcomponent, all configured to dispose first ink layer 430 within the gap(G) formed between body 404 and antenna window 410. As discussed hereinwith respect to FIG. 2, first ink layer 430 is formed from a curable,colored ink that includes unique properties, as discussed herein.

As shown in FIG. 4D, first ink layer 430 is disposed within the gap (G)(see, FIG. 4B) and substantially surrounds protrusion 424 of insert 412.Additionally, first ink layer 430 includes a surface 432A, correspondingto the surface of first ink layer 430 prior to performing a curingprocess for first ink layer 430. As shown in FIG. 4D, surface 432A ispositioned below exposed surface 426 of body 404 and exposed surface 428of antenna window 410, respectively. As such, unoccupied or unfilledspace within the gap (G) exists between surface 432A of first ink layer430 and the exposed surfaces 426, 428 of body 404 and antenna window410, respectively.

Turning to FIG. 4E, and with comparison to FIG. 4D, first ink layer 430is shown after or subsequent to performing a curing process. That is,FIG. 4E shows first ink layer 430 after the curable, colored ink formingfirst ink layer 430 undergoes a curing process. As shown in FIG. 4E, andwith comparison to FIG. 4D, curing first ink layer 430 results in theshrinkage (and/or other thickness reduction) of first ink layer 430 andthe curable, colored material forming first ink layer 430. Thepost-cured surface 432B of first ink layer 430 is positioned below thepre-cured surface 432A of first ink layer 430, as discussed herein. Thecuring process performed on first ink layer 430 can include, but is notlimited to, a thermal curing process or an ultraviolet (UV) curingprocess, and is dependent upon the type of curable ink forming first inklayer 430.

Additionally as a result of performing the curing process, first inklayer 430 is bonded to protrusion 424. Specifically, first ink layer 430is bonded to surface 438 of protrusion 424 and the other portions ofprotrusion 424 which first ink layer 430 contacts. First ink layer 430is bonded to protrusion 424 as a result of curing first ink layer 430,the material composition of the curable, colored ink of first ink layer430 and/or the material composition of protrusion 424 of insert 412.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIGS. 4C-4E corresponds to operations304 and 306 of the process 300 shown in FIG. 3.

FIGS. 4F and 4G show second ink layer 434 disposed in the gap (G) (see,FIGS. 4A and 4B) formed between body 404 and antenna window 410.Additionally as shown in FIGS. 4F and 4G, second ink layer 434 isover-disposed or printed within the gap (G), and as a result, a portionof second ink layer 434 is disposed over a portion of body 404 andantenna window 410. Similar to FIG. 4C, second ink layer 434 is disposedwithin the gap (G) and on portions of body 404 and antenna window 410using an ink dispensing component 440.

As shown in FIG. 4G, a portion of second ink layer 434 is disposedwithin the gap (G) over surface 432 of first ink layer 430.Additionally, second ink layer 434 is disposed over exposed surface 426of body 404 and exposed surface 428 of antenna window 410, respectively.Second ink layer 434 is disposed over first ink layer 430, body 404 andantenna window 410 to ensure that the gap (G) formed between body 404and antenna window 410 is substantially filled, and/or to ensure thatfirst ink layer 430 is substantially protected from damage by second inklayer 434, as discussed herein. Second ink layer 434 is formed from acurable, clear or transparent ink having unique properties and/orcharacteristics, as discussed herein with respect to FIG. 2 anddiscussed below.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIGS. 4F and 4G corresponds tooperation 308 of the process 300 shown in FIG. 3.

FIGS. 4H and 4I show at least a part of second ink layer 434 removedprior to performing a curing process. Specifically, as shown in FIG. 4I,at least a part of second ink layer 434 previously disposed over firstink layer 430, body 404 and antenna window 410 is removed. Withcomparison to FIG. 4G, second ink layer 434 (formed over first ink layer430, exposed surface 426 of body 404 and exposed surface 428 of antennawindow 410) has a reduced thickness, as a result of removing a part ofsecond ink layer 434. The removal of an excess part of second ink layer434 can be achieved by scraping second ink layer 434 from first inklayer 430, body 404 and antenna window 410. As shown in FIG. 4H, an inkremoval tool 442 can be used to remove and/or scrape an excess part ofsecond ink layer 434 to reduce the thickness and/or amount of second inklayer 434 disposed over first ink layer 430, body 404 and antenna window410. In non-limiting examples, ink removal tool 442 can be a blade(e.g., doctor blade), a flexible scraper, or the like that is configuredto remove a part of second ink layer 434.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIGS. 4H and 4I corresponds tooperation 310 of the process 300 shown in FIG. 3.

FIG. 4J shows a cross-section view of housing 402 subsequent toperforming a curing process on second ink layer 434 and the curable,transparent or clear ink forming second ink layer 434. As shown in FIG.4J, and with comparison to FIG. 4I, curing second ink layer 434 resultsin the shrinkage of second ink layer 434 and the curable, clear inkforming second ink layer 434. Pre-cured surface 436A (shown in phantom)and post-cured surface 436B of second ink layer 434 are shown in FIG.4J. The post-cured surface 436B of second ink layer 434 is positionedbelow the pre-cured surface 436A of second ink layer 434 as a result ofsecond ink layer 434 shrinking during the curing process.

However, and as discussed herein with respect to FIG. 2, second inklayer 434 is formed from a material having low-shrinkage propertiesand/or characteristics. As a result, the shrinking of second ink layer434 during the curing process is substantially small and/or negligible.Having low-shrinkage properties and/or characteristics for second inklayer 434 can ensure that second ink layer 434 exposed in housing 402 isnot formed substantially below body 404 and antenna window 410, whichwould create an undesirable transition between body 404 and antennawindow 410 in housing 402. Specifically, as shown in FIG. 4J, second inklayer 434 can shrink a minimal amount, such that surface 436B ispositioned below exposed surface 426 of body 404 and exposed surface 428of antenna window 410 by less than approximately 5 μm in one embodiment.A 5 μm (or smaller) difference in surface separation between surface436B of second ink layer 434 and body 404/antenna window 410 may not betactilely detectable by a human, as discussed herein. Additionally, morelayers can be applied to remediate a thickness loss/shrinkage of thesecond ink layer. As similarly discussed herein with respect to FIG. 4E,the curing process performed on second ink layer 434 can include, but isnot limited to, a thermal curing process or an ultraviolet (UV) curingprocess, and is dependent upon the type of curable ink forming first inklayer 430.

Additionally as a result of performing the curing process, second inklayer 434 is bonded to first ink layer 430. Specifically, second inklayer 434 is bonded to surface 432B of first ink layer 430. Second inklayer 434 is bonded to first ink layer 430 as a result of curing secondink layer 434, the material composition of the curable, clear ink ofsecond ink layer 434 and/or the material composition of the curable,colored ink of first ink layer 434.

Additionally, and for similar reasons, curing second ink layer 434 alsoresults in the prevention of a bond (or formation of a weak bond) beingformed between second ink layer 434 and body 404/antenna window 410.That is, the material composition of the curable, clear ink of secondink layer 434 and/or the material composition of body 404 and antennawindow 410 can prevent second ink layer 434 from bonding (or permit onlyweakly bonding) to body 404 and antenna window 410, respectively. Asdiscussed herein with respect to FIG. 2, the curable, clear ink formingsecond ink layer 434 can be compositionally configured to not bond (orbond weakly) with specific types of materials (e.g., metals) when secondink layer 434 undergoes a curing process. Preventing the bond (and/orpermitting a weak bond) from being formed between second ink layer 434and body 404/antenna window 410 can aid in the removal of second inklayer 434 from body 404 and antenna window 410, as discussed herein.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIG. 4J corresponds to operation 312 ofthe process 300 shown in FIG. 3.

FIGS. 4K and 4L show the remaining part of second ink layer 434 disposedover body 404 and antenna window 410 removed from housing 402.Specifically, the parts and/or residues of second ink layer 434 thatwere not previously removed by ink removal tool 442 (see, FIG. 4H) priorto curing second ink layer 434 are removed subsequent to performing thecuring process on second ink layer 434. The parts and/or residues ofsecond ink layer 434 removed from exposed surface 426 of body 404 andexposed surface 428 of antenna window 410 are removed using a solvent.Specifically, the parts and/or residues of second ink layer 434 stilldisposed on body 404 and antenna window 410 are exposed to a solvent. Asa result of no bond (or weak bonding) being formed between second inklayer 434 and body 404/antenna window 410 during the curing process, asdiscussed above, the solvent can substantially surround and/or penetratethe parts of second ink layer 434 still disposed over body 404 andantenna window 410 and dissolve and/or break down the ink. Subsequent tobeing exposed to the solvent, second ink layer 434 (and/or its residues)is then removed, scraped or wiped away from the exposed surfaces 426,428 of body 404 and antenna window 410, respectively, after the solventsubstantially dissolves or breaks down second ink layer 434. In anon-limiting example, the solvent used to remove the parts of curedsecond ink layer 434 disposed over body 404 and antenna window 410includes isopropyl alcohol (IPA). However, it is understood that othersuitable solvents can be used to remove the cured parts of second inklayer 434 from body 404 and antenna window 410. Additionally, the secondink layer residues can first be removed with a tape, followed by wipingwith a solvent.

FIG. 4L shows housing 402 as a final product that can be implemented foruse with an electronic device, as discussed herein. As shown in FIG. 4L,and as discussed herein with respect to FIG. 2, second ink layer 434 isformed over first ink layer 430 to protect first ink layer 430 and/orprevent first ink layer 430 from being directly exposed within housing402. Additionally, because second ink layer 434 is formed from a clearor transparent ink, and first ink layer 430 is formed from a coloredink, the colored ink of first ink layer 430 is visible in housing 402through second ink layer 434.

Additionally as shown in FIG. 4L, and as previously discussed hereinwith respect to FIG. 4J, exposed surface 436 of second ink layer 434 ispositioned below exposed surface 426 of body 404 and exposed surface 428of antenna window 410, respectively. However, because second ink layer434 has a low-shrinkage chemical and/or material composition, exposedsurface 36 is only positioned below exposed surface 426 of body 404 andexposed surface 428 of antenna window 410 a distance of approximately 5μm. In this embodiment, the distance in which exposed surface 436 ispositioned below exposed surface 426 of body 404 and exposed surface 428of antenna window 410 is sufficiently small that user of housing 402 maynot tactilely perceive the transition between body 404, antenna window410 and second ink layer 434 positioned in the gap (G) therebetween. Assuch, although housing 404 is formed from distinct portions (e.g., body404, antenna window 410), second ink layer 434 disposed in the gap (G)makes the transition from and/or over the surface of housing 202 feelcontiguous. As such, the structural discontinuities of housing 202 aretactilely and/or visually imperceptible to a user of housing 202,although this may not be true in all embodiments and there is norequirement that any embodiment have a tactile imperceptibility, avisual imperceptibility, or both at a gap or transition.

The process performed on body 404 and antenna window 410 as shown anddiscussed herein with respect to FIGS. 4K and 4L corresponds tooperation 314 of the process 300 shown in FIG. 3.

FIG. 5 shows housing 502 according to an additional embodiment. Housing502 includes substantially similar components and portions as discussedherein with respect to FIGS. 1A-2 and 4A-4L. Redundant explanation ofthese components is omitted for clarity.

As shown in FIG. 5, insert 512 is coupled and/or adhered to body 504 andantenna window 510, and includes protrusion 524 extending into a portionof the gap (G) (see, FIG. 2) formed between body 504 and antenna window510, as similarly discussed herein. However, as opposed to certain ofthe inserts discussed herein, insert 512 includes a predetermined ordesired color. Similar to first ink layer 230 discussed herein withrespect to FIG. 2, insert 512 includes a desired color thatsubstantially matches and/or corresponds to the color of body 504 andantenna window 510. As discussed herein, the desired color of insert 512is visible in the gap (G) formed in housing 502.

Housing 502 only includes a single ink layer 544 disposed within the gap(G) formed between body 502 and antenna window 510. As shown in FIG. 5,and similarly discussed herein, single ink layer 544 is disposed withinthe gap (G) and is disposed over and/or covers insert 512. Additionally,single ink layer 544 includes an exposed surface 546 positioned adjacentand/or minimally (e.g., less than 5 μm) below exposed surface 526 ofbody 504 and exposed surface 528 of antenna window 510, respectively.Single ink layer 544 is formed from a curable, clear or transparent ink,similar to the ink forming second ink layer 234 discussed herein withrespect to FIG. 2. As a result of forming single ink layer 544 from aclear or transparent ink, the color of insert 512 is visible in the gap(G) of housing 502, through single ink layer 544.

FIGS. 6A and 6B show front and back views of an electronic device 600that utilizes housing 602, as discussed herein with respect to FIGS.1A-5. Specifically, electronic device 600 includes housing 602 includingbody 604, antenna window 610 and a gap (G) (see, FIG. 1B) formed betweenbody 604 and antenna window 610 at an end 608 of housing 602. The gap(G) is sized to allow electromagnetic waves of an antenna (not shown) tobe transmitted through housing 602 and/or between body 604 and antennawindow 610. As shown in FIG. 6, electronic device 600 is implemented asa tablet computing device. Other embodiments can implement electronicdevice 600 differently, such as, for example, a mobile phone, a laptopor desktop computer, a gaming device, a display, a digital music player,a wearable computing device or display, a health monitoring device, andso on.

Electronic device 600 includes a housing 602 at least partiallysurrounding a display module, a cover 646 substantially covering thedisplay module and one or more buttons or input devices 648. Housing 602can form an outer surface or partial outer surface and protective casefor the internal components of the electronic device 600 and at leastpartially surrounds the display module positioned within an internalcavity formed by housing 602. Housing 602 can be formed of one or morecomponents operably connected together, such as a front piece and a backpiece (not shown). Alternatively, housing 602 can be formed of a singlepiece operably connected to the display module. Housing 602 is formedfrom the ceramic material discussed herein, and as a result, undergoesthe proof testing process using the testing system prior to beingimplemented in and/or forming a portion of electronic device 600.

The display module is substantially surrounded by housing 602 and/or ispositioned within an internal cavity formed by housing 602, such thatthe display module is substantially protected on almost all sides byhousing 602. Cover 646 also protects the display module of electronicdevice 600. Specifically, cover 646 is formed integral with and/or iscoupled to housing 602 to substantially cover and protect the displaymodule. Cover 646 covers at least a portion of the front surface ofelectronic device 600. When a user interacts with the display module ofelectronic device 600, the user touches or contacts cover 646. Similarto housing 602, cover 646 of electronic device 600 can be a brittlecomponent and is therefore formed from the ceramic material discussedherein. The ceramic material forming cover 646 can undergo the prooftesting process performed by the testing system discussed herein withrespect to FIGS. 1A-6B. By performing the proof testing process on theceramic material forming cover 646, it is ensured that the ceramicmaterial forming cover 646 meets the quality and/or strength standardrequired for implementation within electronic device 600 and/or cover646 and includes desired functional, operational and/or physicalcharacteristics and properties.

Button 648 can take the form of a home button, which may be a mechanicalbutton, a soft button (e.g., a button that does not physically move butstill accepts inputs), an icon or image on a display, and so on.Further, in some embodiments, button 648 can be integrated as part ofcover 646 of the electronic device 600. Button 648, like housing 602 andcover 646, is a brittle component of electronic device 600 and, as aresult, is formed from the ceramic material that undergoes the prooftesting process as discussed herein.

It should be appreciated that certain dimensions, distances, depths, andso on may be exaggerated in the accompanying figures in order to moreclearly illustrate certain aspects of embodiments. Accordingly, thefigures are illustrative only and are not meant to convey exactrelationships between elements, exact dimensions, tolerances, or thelike.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedembodiments. Thus, the foregoing descriptions of the specificembodiments described herein are presented for purposes of illustrationand description. They are not targeted to be exhaustive or to limit theembodiments to the precise forms disclosed. It will be apparent to oneof ordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

What is claimed is:
 1. A housing for an electronic device comprising: afirst portion comprising an opening; a second portion positioned withinthe opening; a protrusion extending into a gap formed between the firstportion and the second portion; a first ink layer disposed within thegap and substantially surrounding the protrusion; and a second ink layerdisposed within the gap and over the first ink layer; wherein the firstportion, the second ink layer, and the second portion cooperate to forma substantially contiguous surface; and the second ink layer ispositioned approximately 5 microns (μm) or less below an exposed surfaceof the first portion and an exposed surface of the second portion. 2.The housing of claim 1, wherein the protrusion is positionedapproximately 50 μm to 200 μm below the exposed surface of the firstportion and the exposed surface of the second portion.
 3. The housing ofclaim 1, wherein at least one of the first ink layer, the second inklayer or an insert substantially seals the gap formed between the firstportion and the second portion.
 4. The housing of claim 1, wherein thegap formed between the first portion and the second portion is sized toallow electromagnetic waves to pass between the first portion and thesecond portion.
 5. The housing of claim 1, wherein: a transition betweenthe first portion and the second ink layer is tactilely imperceptible;and a transition between the second portion and the second ink layer istactilely imperceptible.
 6. The housing of claim 8, wherein the secondink layer is disposed on the surface of the first ink layer.
 7. A methodof forming a housing for an electronic device, comprising: coupling aninsert to a first portion and a second portion of the housing, aprotrusion of the insert extending within a gap between the firstportion and second portion; disposing a first ink layer within the gap;curing the first ink layer; disposing a second ink layer within the gapand over the first ink layer, an exposed surface of the first portion,and an exposed surface of the second portion; removing at least part ofthe second ink layer; and curing the second ink layer; wherein a topsurface of the second ink layer is within 10 microns of a top surface ofthe second portion of the housing.
 8. The method of claim 7, furthercomprising removing part of the second ink layer disposed over theexposed surface of the first portion of the housing or the exposedsurface of the second portion of the housing.
 9. The method of claim 7,wherein removing the part of the second ink layer comprises scraping atleast the part of the second ink layer from the exposed surface of thefirst portion and the exposed surface of the second portion using an inkremoval tool.
 10. The method of claim 7, wherein coupling the insert tothe first portion and the second portion of the housing comprisesadhering the insert to an interior surface of the first portion and aninterior surface of the second portion.
 11. The method of claim 7,wherein disposing the first ink layer within the gap comprisessubstantially covering the protrusion with the first ink layer.
 12. Themethod of claim 7, wherein curing the first ink layer comprises bondingthe first ink layer to the insert.
 13. The method of claim 7, whereincuring the first ink layer comprises shrinking the first ink layer. 14.The method of claim 7, wherein curing the second ink layer comprises:bonding the second ink layer to the first ink layer; and substantiallypreventing a strong bond from forming between the second ink layer andat least one of the exposed surface of the first portion of the housingand the exposed surface of the second portion of the housing.
 15. Themethod of claim 7, further comprising: bonding the second ink layer tothe first ink layer; and locally curing only portions of the first andsecond ink layers located inside the gap.
 16. The method of claim 7,wherein curing the second ink layer comprises shrinking the second inklayer.
 17. An electronic device comprising: a housing comprising: a bodyincluding an opening formed in an end of the housing; and an antennawindow positioned within the opening of the body, the antenna windowseparated from the body via a gap; a plastic insert coupled to thehousing and the antenna window, the plastic insert comprising aprotrusion extending into a portion of the gap between the housing andthe antenna window; and at least one ink layer disposed within the gap,the at least one ink layer exposed between the housing and the antennawindow.
 18. The electronic device of claim 17, wherein: the at least oneink layer is formed from a substantially clear and transparent ink; andthe desired color of the plastic insert is visible between the body andthe antenna window through the substantially clear and transparent ink.19. The electronic device of claim 17, wherein a first ink layer isformed from a colored ink.
 20. The electronic device of claim 17,wherein a second ink layer is formed from a clear ink, the clear inkallowing the colored ink of the first ink layer to be visible betweenthe body and the antenna window.